Superior stain resistant decorative floor covering and its method of manufacture

Abstract

A surface treatment composition of the present invention comprises (A) urethaneacrylate oligomer, (B) acrylate based monomer, (C) photoinitiator, (D) silicon additive, and (E) silica matting agent. The present invention provides a surface treatment composition in which imparts abrasion and scratch resistance to the surface of a soft type urethaneacrylate oligomer decorative floor covering, and ameliorates the problem of low stain resistance caused a low density of elaborate crosslinks by using a small amount of single functional group monomer. The present invention also provides a surface treatment composition in which employs only hard type urethaneacrylate without single functional group monomer so that cross linking density is increased and the effects of oxygen that prohibits the surface curing are minimized, resulting in improved stain resistance. Additionally, this invention provides a surface treatment composition in which a mixture of soft type and hard type urethaneacrylate oligomer and a mixture of acetophenone and benzophenone photoinitiator are used, and a tertiary amine compound reaction promoter is added. Furthermore, this invention provides a surface treatment composition in which mixed soft and hard type urethaneacrylate oligomer is used, acetophenone photoinitiator is added, and ultraviolet light (UV) curing is performed under a nitrogen gas environment. The stain resistance of a decorative floor covering in which a surface treating sub-layer is formed by UV curing after an above surface treatment composition is coated is excellent.

What is claimed is:  
     
       1. A decorative floor covering comprising a backing layer, a substrate layer, and a surface layer, wherein the backing layer is comprised of one of a foaming sub-layer and a mechanical foaming sub-layer, wherein the surface layer is comprised of a printing sub-layer, and a skin sub-layer, and wherein a surface treating sub-layer is formed on the skin sub-layer by ultraviolet light (UV) curing a surface treatment composition comprising 
       40 weight parts of urethaneacrylate oligomer;  
       acrylate based monomer comprised of 7 to 11 weight parts of single functional group monomer, 34 to 43 weight parts of bi-functional group monomer, and 0 to 5 weight parts of tri-functional group monomer;  
       4 weight parts of acetophenone photoinitiator;  
       1 weight part of reactive silicon additive; and  
       5 weight parts of silica matting agent.  
     
     
       2. A decorative floor covering in accordance with  claim 1 , wherein the backing layer further comprises a sizing sub-layer. 
     
     
       3. A decorative floor covering in accordance with  claim 1  wherein the surface layer further comprises one of a foaming sub-layer and a non-foaming sub-layer. 
     
     
       4. A decorative floor covering in accordance with  claim 1  wherein the single functional group monomer is selected from a group comprised of 2-hydroxyethylacrylate, 2-hydroxypropylacrylate, and a mixture thereof and wherein the bi-functional group monomer is selected from a group comprised of 1,6-hexanedioldiacrylate, tripropyleneglycoldiacrylate, and a mixture thereof; and wherein the tri-functional group monomer is selected from a group comprised of trimethylolpropanetriacrylate, trimethylolpropaneethoxytriacrylate, and a mixture thereof.